Attachment_1_-_SPECIFICATION_RUDDER_ASSEMBLY_P-562-0300_revised_03-29-2016_(2).doc

Inspection and Overhaul Specification for

225 Ft. WLB Rudder Assembly

P-562-0300, Rev B

REVISION B

Date: Dec. 21, 2015 Reviewed: 04/04/2016

INSPECTION AND OVERHAUL SPECIFICATION

For

225’ WLB RUDDER ASSEMBLY

P-562-0300

ORIGINATED BY: A. Ollerman

DATE: 12/21/2015.

ORIGINATOR’S COMMAND: Surface Forces Logistics Center (SFLC) IBCT-PL

1.0 Scope: This specification defines the inspection, overhaul, testing and packaging requirements for a rudder assembly used on 225 foot WLB class buoy tenders in the United States Coast Guard. The assembly includes rudder, rudder stock and related components as required by this specification.

1.1 Government Furnished Property (GFP):

(a) Used (turn-in) Rudder Blade

(b) Used (turn-in) Rudder Stock

2. 0 Applicable Documents;

2.1 USCG Drawings:

a) 225B-WLB-561-003 Steering Gear Arrangement, Rev. A, Dated 3/22/2001

b) 225B-WLB-562-001 Steering Components Arrangement and Detail, Rev. F, Dated 11/05/2015

c) 225B-WLB-562-002 Rudder Structural A & D, Rev. C, Dated 5/30/2003

d) 225B-WLB-562-003 RUDDER ASSEMBLY FOR LOGISTICS & SUPPORT NSN 2040-01-507-7034, RevA, Dated 2/12/2009

2.2 Military Specifications:

a) MIL-A-22262B (SH), Abrasive Blasting Media Ship hull Blast Cleaning, Dtd. 21 Mar. 96

b) MIL-PRF-16173E, Corrosion Preventive Compound Solvent Cutback, Cold Application, Dated 6/January/1993.

c) MIL-PRF-24647C, Paint System, Anticorrosive and Antifouling, Ship Hull Dated 24/September/2001.

d) USCG SFLC Specification P-243-0145, Propulsion Shaft & Rudder Stock Blank Finish Machining Specification, Dated April 1993.

e) NAVSEA S9243-AW-TRS-012/0203-086-501A, Surface Ships Main Propulsion Shafting Examination, Test and Repair Action Record

f) SFLC-Std-Spec-0740, Welding and Allied Processes, Appendix- C Non-Destructive Testing

2.3 Technical Manual: None

2.4 Commercial Documents:

a) American Welding Society (AWS) Specification D1.1 Structural Welding Code, Steel, 2000 edition.

b) The Society for Protective Coatings, SSPC-SP 10, Near White Blast Cleaning, Sept. 2000 edition.

c) The Society for Protective Coatings, NACE NO. 5/SSPC-SP12, Joint Surface Preparation Standard.

d) National Conference of Standards Labs, ANSI/NCSL Z540-1 Calibration Laboratories and Measuring Equipment, dated Jan, 1994.

2.5 Coast Guard SFLC Bar Coding Specification: D-000-0100, dated 2/06. REV G

2.6 Document Sources: See section 6.0 for sources of the above listed documents.

2.7 Precedence: In the event of a conflict between the text of this specification and the references cited herein this specification shall take precedence. Nothing in this specification supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. 0 Requirements: Described below are the requirements the Contractor shall follow for the overhaul of rudder assemblies inducted for overhaul.

3.1 General – The overhaul requirements described herein are the minimum necessary and are not intended to replace any procedures, controls, examinations or test normally employed by the contractor to ensure quality of the product.

3.1.1. The Contractor must be capable of lifting and handling a rudder stock weighing approximately 12,300 lbs and a rudder blade weighing approximately 14,400 lbs.

3.1.2. The Contractor must be capable of machining a rudder stock measuring approximately 16 feet long and a rudder blade measuring approximately 9 feet long by 12 feet high.

3.2 Preliminary Inspection – Preliminary disassembly, cleaning, preparation and inspection shall be conducted of all received components. The contractor shall measure all critical areas and perform a receipt blue fit. The contractor shall note the condition of the shipping container and its contents.

3.2.1 Condition Found Report (CFR) (CLIN 0001-4001) – Upon completion of the inspection, and within forty-five (45) calendar days after receipt of rudder assembly, the contractor shall submit an individual written inspection report for each item inducted for overhaul. The report, at a minimum, shall include the following information:

a. Contractor Name and address, with name and signature of person responsible for performing inspection

b. Date rudder assembly was received

c. Serial Number of rudder assembly

d. Container condition

e. Disassembly and inspection findings summary

f. Measurements, photos, and details of deficient areas.

g. A list of parts necessary, and recommended repairs needed to complete the overhaul. This shall include part numbers (as applicable), quantities, and parts priced individually. The contractor shall make the rudder-blade/rudder-stock a matched assembly conforming to print and ready for return to service.

h. Cost to repair or replace the existing shipping container, if needed.

i. Labor required to complete overhaul

j. Total cost to complete overhaul, inclusive of preservation, packaging and marking as specified in the contract/specification.

3.2.2 Authority to Proceed with Overhaul - The contractor shall not begin or perform any repair or part replacement until authorized in writing by the Contracting Officer to proceed. The authorization may provide disposition instructions regarding disposal of any item determined to be beyond economical repair (BER) (CLIN 0001b-4001b). If instructed to scrap BER material at the Contractor’s facility, the Contractor shall submit form SF-1424 (Inventory Disposal Report) to the Contracting Officer within 30 days of BER determination. The requirements of paragraph 3.3 below are considered a standard overhaul. If the upper rudder nut, lower rudder nut, or rudder stock are deemed BER, the Contracting Officer may authorize the Contractor to manufacture these items. The requirements set forth in paragraph 3.4 below will then apply.

3.3 Overhaul Requirements – Upon the acceptance of the CFR and after authorization to proceed has been granted by the Contracting Officer, the contractor shall provide the labor and materials to overhaul each Rudder Assembly. (CLIN 0001a-4001a). Delivery of each overhauled, preserved, packaged, and marked Rudder Assembly shall be within 120 calendar days from authorization to proceed with overhaul.

3.3.1 Materials, Rudder Assembly: All materials shall be in accordance with the applicable drawing and piece number. Contractor shall provide material certifications to the Coast Guard Quality Assurance Representative during the inspection phase of the contract.

3.3.2 Stock: Stock shall be dimensionally checked to be in conformance with drawing 225-WLB-562-001 Piece 3. The Total Indicated Run-Out (TIR) shall be not greater than .002” on any taper or bearing surface and no greater than .005” in all other locations.

3.3.3 Blade Thickness: Blade shall be Ultra Sonic Thickness (UT) checked in accordance with SFLC –Std-Spec-0740 and Drawing 225-WLB-562-002, in a grid pattern of 1 shot per square foot over the entire surface of the rudder blade with special attention paid to the leading edge. A report with a diagram of the rudder blade and the measured thicknesses shall be provided to the USCG representative for review and approval.

3.3.4 Keys: Keys shall be inspected and renewed if not conformance with piece 14 of drawing 225-WLB-562-001. Any replacement keys will have a minimum 70,000 yield in lieu of 60,000 as stated by General Note 7. General note 7 is determined to be in error. All keys shall be fitted to their prospective keyways to allow for a “tapfit” using a wood block or soft mallet.

3.3.5 Fits: Each assembly component shall be manufactured in accordance with its referenced drawing and piece number, or letter designation as the case may be. Fitted components (i.e. tapers and threads) shall be matched to its mating component in order that the assembly is ready for installation on the cutter.

3.3.6 The rudder stock taper shall be fitted to the rudder hub taper. Taper to taper fit shall be within a 80% to 99% range as a minimum. Removal of material necessary for fitting shall be from the rudder hub bore only. (CLIN 0005-4005) Material will be removed from the rudder bore by the use of a fixed boring machine. No hand grinding is allowed. No material shall be removed from the stock taper.

a) A record of the blue fit test with overall fit percentage shall be maintained.

3.3.7 Renew Fairing Compound Find #9, 225-WLB-562-002.

3.4 Contingency Parts: The following shall apply if the rudder stock, upper rudder nut, or lower rudder nut require manufacture to complete the requirements of paragraph 3.3:

3.4.1 Machine new rudder stock from blank (CLIN 0002-4002): Refer to SFLC Specification P-243-0145 (reference 2.2d), using Data Sheet number 314. Packaging and marking shall be accomplished in accordance with this specification. Rudder stock blank shall be furnished by the Government under Activity Control Number (ACN) 2040-01-F98-0204.

3.4.2 Machine new upper rudder nut (CLIN 0003-4003): Contractor shall furnish labor and materials to manufacture upper rudder nut, Find No. 12 on reference 2.1b.

3.4.3 Machine new lower rudder nut (CLIN 0004-4004): Contractor shall furnish labor and materials to manufacture lower rudder nut, Find No. 13 on reference 2.1.b.

3.5 Welding:

3.5.1 Weld Quality: All welds shall be thoroughly fused with base metal. Welds shall be free of craters, undercutting, overlaps, porosity, or cracks. All welding shall conform to AWS D1.1.

3.5.2 Welder Qualification: Welders shall have a valid qualification record certified by one or more of the following organizations. This qualification shall be for the same particular service application, filler material type, position of welding, and welding process.

a) The American Welding Society

b) The American Bureau of Shipping

c) Department of the Navy

3.5.2.1 Contractor shall make welder certifications available to the Contract Administrator prior to contract award. A copy of the welder certifications shall also be available for the Coast Guard Quality Assurance Representative.

3.6 Flow Coating, Rudder Interior: The rudder internal cavity shall be flow coated with using a suitable thread sealer after completion of flow coating.

3.7 Painting, Rudder Blade Exterior:

3.7.1 Surface Preparation: In preparation for painting the rudder exterior surface shall be sand blasted to near white metal in accordance with SSPC-SP10/NACE No. 2 using grit conforming to MIL-A-22262. Blasting shall result in an anchor profile of 1.5 to 3.5 mils. All machine finished surfaces at risk of damage from sand blast and paint operations shall be blanked off or otherwise protected while this work is being performed.

a) Alternative Method: To NACE NO. 5/SSPC-SP12 to WJ-2 and SC-1.

3.7.2 Paint Coating: Paint coating shall be two coats, 5 to 6 mils dry film thickness of anti-corrosive Epoxy in accordance with MIL-PRF-24647, color Red (11105)

3.8 Painting, miscellaneous items:

3.8.1 As depicted in view 7-a of reference 2.1a, the un-machine surfaces of the tiller arm, retainer plate and bearing housing exterior surfaces shall be sand blasted to near white metal in accordance with SSPC-SP10/NACE No. 2 using grit conforming to MIL-A-22262. Blasting shall result in an anchor profile of 1.5 to 3.5 mils. All machine finished surfaces at risk of damage from sand blast and paint operations shall be blanked off or otherwise protected.

3.8.1.1 The above items, in 3.7.1, shall have one coat, 3 to 4 mils dry film thickness of inorganic zinc paint to DOD-P-24648, color green or grey applied.

3.8.2 The rudder nut and areas of the rudder stock shall be coated per general note 9 of reference 2.1.b. The surfaces shall be free of rust and solvent cleaned prior to application. The area of the rudder stock to be coated is identified as the 17” diameter and the taper transition area, but not to include the 16” diameter.

3.9 Notifications & Inspections: The contractor shall be responsible for notifying the Contracting Officer in writing no less than seven (7) calendar days prior to the contractor being ready for any Quality Assurance (Q.A.) inspections or testing required herein.

4.0 Quality Assurance (QA):

4.1 General: The Contractor is responsible for the conformance and overall quality of each item offered to the Coast Guard for acceptance or approval.

4.2 Responsibility for Inspection: The Contractor shall be responsible for the performance of all inspection requirements specified herein. The Contractor shall provide space, personnel and test equipment for the conduct of all inspection requirements. The space provided must be a minimum of 2,000 square feet and contain the inspection, test equipment and necessary cranes for rudder blade and rudder stock handling. All inspection and testing shall be performed at the Contractors facility prior to the Coast Guards acceptance of the contracted items. The Coast Guard reserves the right to verify or have performed any of the inspections set forth herein where such inspections are deemed necessary to assure that supplies and services conform to prescribed requirements. The contractor shall notify the Contracting Officer in writing of the scheduled commencement of any inspections required by this specification.

4.3 Responsibility for Compliance: All items shall meet the provisions of Sections 3 & 5. The inspections set forth in this specification shall become part of the contractor's overall inspection system or quality program. The absence of any inspection requirements in the specification shall not relieve the contractor of the responsibility of assuring that all products or supplies submitted to the government for acceptance comply with all requirements of the contract. Sampling for quality conformance does not authorize submission of known defective material (either indicated or actual) nor does it commit the government to acceptance of defective material.

4.4 Inspection System: The Contractor shall maintain an inspection system, which shall ensure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be in accordance with ANSI/ASQC-A9003-1994. The system shall be documented and available for review by the Coast Guard inspector.

4.5 Inspections & Tests: The inspections & tests required herein are the minimum necessary and are not intended to replace any controls, examinations, or tests normally employed by the contractor to assure the quality of the product. The following are required:

a) Verification of all dimensional tolerances, lengths, diameters etc. and thickness checks.

b) Provide certificates of material conformance to verify that materials used conform to the material requirements of the applicable drawings and this specification.

c) Welding requirements and welder certifications conform to part 3.5.

d) Blue fit test record and record of taper gage set certification as required by part 3.3.3.

e) Verify flow coating and paint requirements conformance with parts 3.6 through 3.8.

f) Inspection of Preservation, Packaging and Marking (PP&M) as required by part 5.0 of this specification.

4.6 Calibration System: The Contractor shall be required to maintain a test equipment calibration program in compliance with ANSI/NCSL Z540-1. The program shall be documented and traceable to the National Institute of Standards (NIST). The calibration system records shall be maintained for inspection for the duration of any contract referencing this specification

4.7 Test & Inspection Reports: A copy of any standard contractor test or inspection report shall be turned over to the Coast Guard Q.A. Representative upon his arrival at the contractor's plant.

5.0 Preservation, Packaging & Marking (PP&M), Rudder Assembly (Preliminary): Packed rudder assemblies shall be preserved, packed and marked to withstand outdoor storage with only the cover of a tarp or shrink wrap for protection from the elements.

5.1 Preservation: All unpainted pieces or surfaces subject to corrosion if left unprotected shall be coated with corrosion preventative compound, Grade 3 in accordance with MIL-C-16173. Preservation is further defined in the following packaging requirements.

5.2 Packaging, Rudder Assembly: With the exception of the rudder blade, all rudder assembly components shall be packed in skid mounted wood shipping containers that are suitable for repeated use. Each container shall have a lid that is attached with self-tapping wood screws for easy removal and reattachment. As a general requirement, all containers shall be capable of supporting the packed item(s) in order to maintain stability and protection to the item(s) during shipping by commercial carrier. Interior blocking and cradles shall be used where necessary to support the packed item(s). Individual shipping containers are further defined in the following paragraphs.

a) Stock: The rudder stock shall be packed with upper and lower stock nuts installed and all keys (4 each) fitted with their securing screws. Apply generous coating preservative compound to all keys and nuts including threaded areas prior to installation on the rudder stock. Rudder stock shall be supported in its container with a minimum of four (4) evenly spaced support cradles suitably located throughout the shaft length.

b) Rudder Blade: The rudder blade container may be an “open type” wood crate. Apply a generous coating of preservative compound to all unpainted metal surfaces such as the taper area and wrap the entire rudder blade moisture barrier material prior to packing.

c) Remaining Items: Remaining assembly items shall be packed in one (1) or (2) fully enclosed containers as necessary. Ensure placement of all packed items with suitable blocking and cushioning as necessary to ensure safety and protection to the items during shipping. Ensure that all material subject to corrosion are properly preserved and wrapped prior to packaging.

5.3 Marking: Mark each shipping container with the following information:

NSN : 2040-01-507-7034

Name :RUDDER, ASSEMBLY

Drawing Number: 225-WLB-562-003

Serial Number: (fill in) .

Weight: (fill in) .

The following statement: "Coast Guard SFLC Material, Condition Code "A"

5.3.1 Additional Marking; In addition to the above markings, each container included in each rudder assembly shall be marked as follows:

a) “CRATE 1 OF 4” (or as applicable) shall be marked on the crate containing the rudder blade.

b) “CRATE 2 OF 4” shall be marked on the crate containing the rudder stock.

c) “CRATE 3 OF 4” & “4 of 4” (or as applicable) marked on the remaining containers.

5.4 Bar Coding: The stock number shall also be bar coded in addition to the numerical marking.

a) All bar coded labels shall be in accordance with SFLC Bar Coding specification number D-000-0100.

1) The actual labels shall be Type “V”, Grade “C”, Style 2”, Composition “a”.

2) The Bar Code Label can be applied separately or as part of the marking required in 5.3.

6. 0 Notes:

6.1 Document Sources:

Specification and Standards (DODISS Documents)

Standardizations Document Order Desk

700 Robbins Avenue

Building #4, Section D

Philadelphia, PA 19111-5094

215-697-1187

The Society for Protective Coatings (SSPC)

40 24TH St., Sixth Floor

Pittsburgh, PA 15222

1-412/281-2331

American Welding Society (AWS)

550 NW. LeJeune Road

P.O. Box 351040

Miami, FL 33135

305-443-9353

National Conference of Standards Labs (ANSI/NCSL)

1800 30th St., Suite 305B

Boulder, CO 80301

303-440-3339

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